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Xantrex Technology 120 VAC/60 owner manual With Revision 4.01 Software, Owner’s Manual

Models: 120 VAC/60

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SW Series Inverter/Chargers

With Revision 4.01 Software

Owner’s Manual

 2001 Xantrex Technology, Inc.	Telephone: 360/435-8826	SW Series Inverter/Charger
5916 - 195th Street N. E.	Fax: 360/435-2229	Part No. 2031-5
Arlington, WA 98223	www.traceengineering.com	Rev. C: February 2001

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Xantrex Technology 120 VAC/60 owner manual With Revision 4.01 Software, SW Series Inverter/Chargers, Owner’s Manual

Contents

SW Series Inverter/Chargers With Revision 4.01 SoftwareOwner’s Manual  2001 Xantrex Technology, IncTelephone 360/435-8826  2001 Xantrex Technology, Inc5916 - 195th Street N. E Arlington, WAPRODUCT MATERIALS PACKAGE Telephone 360/435-8826  2001 Xantrex Technology, Inc5916 - 195th Street N. E Arlington, WATABLE OF CONTENTS TABLE OF CONTENTSIMPORTANT SAFETY INSTRUCTIONS CONTROLS, INDICATORS AND COMPONENTSWARRANTY/REPAIR INFORMATION TABLE OF CONTENTSAPPENDIX INDEXTABLE OF CONTENTS INDEX OF FIGURESFigure 1, Identification Label TABLE OF CONTENTS INDEX OF TABLESTable 1, AC Input and Output Wiring Connections GENERAL PRECAUTIONS IMPORTANT SAFETY INSTRUCTIONS IMPORTANT SAFETY INSTRUCTIONSSafety SAVE THESE INSTRUCTIONSSPECIAL NOTICES IMPORTANT SAFETY INSTRUCTIONSWARNING - RISK OF EXPLOSIVE GASSES PageIMPORTANT SAFETY INSTRUCTIONS PERSONAL PRECAUTIONSPage Page IMPORTANT SAFETY INSTRUCTIONS 2001 Xantrex Technology, Inc Telephone 360/435-8826Page INTRODUCTION INTRODUCTIONPage INTRODUCTION 2001 Xantrex Technology, Inc Telephone 360/435-8826MODEL NUMBER UNIT IDENTIFICATION UNIT IDENTIFICATIONPage Figure 1, Identification LabelPage UNIT IDENTIFICATION 2001 Xantrex Technology, Inc Telephone 360/435-8826CONTROL PANEL CONTROLS, INDICATORS AND COMPONENTSDISPLAY Figure 2, SW Series Inverter/ChargerLED STATUS INDICATORS RESET TO FACTORY DEFAULTS BUTTONMENU ACCESS/ADJUSTMENT BUTTONS Black CONTRAST CONTROLAC1 IN GOOD Green ERROR RedAC2 IN GOOD Green BULK YellowREMOTE PORT AC SIDESTACKING PORT INVERTER/CHARGER CIRCUIT BREAKERFigure 5, Internal Components and Indicators INTERNAL COMPONENTS AND INDICATORSLED INDICATORS RY7 Yellow LEDAC SAFETY GROUND BATTERY TERMINALSAUXILIARY AND GENERATOR CONTROL RELAY CONNECTORS Figure 6, Auxiliary and Generator Control Relay ConnectorsPage INSTALLATION INSTALLATIONQUICK INSTALL INSTALLATIONMOUNTING DC CABLINGUNPACKING COMPLETE INSTALLLOCATION INSTALLATIONVENTILATION AC WIRINGFLOW Figure 8, Air Flow Intake LocationTable 1, AC Input and Output Wiring Connections Figure 9, AC Input/Output Power ConnectionWIRE COLOR AC INIMPORTANT PRECAUTION AC INSTALLATION GUIDELINESEXTERNAL TRANSFER RELAYS INSTALLATIONWARNING LABEL 120 VAC GROUND FAULT INTERRUPT OUTLETS GFI’SFigure 10, Warning Label INSTALLATIONBATTERY CABLE SIZING DC WIRINGTable 2, Minimum Recommended Battery Cable Size vs. Cable Length INVERTER MODELDC DISCONNECT AND OVERCURRENT PROTECTION Table 3, Battery Cable To Maximum Breaker/Fuse SizeCABLE SIZE REQUIRED RATING INFigure 11, Battery to Inverter Cable Connection BATTERY CABLE CONNECTIONSINSTALLATION PROCEDURE - BATTERY CABLES INSTALLATIONGEN CONTROL WIRING CONTROL WIRINGAUX RELAY WIRING REMOTE CONTROL WIRINGEQUIPMENT OR CHASSIS GROUNDS SYSTEM GROUNDINGGROUNDING ELECTRODES/GROUND RODS BONDING THE GROUNDING SYSTEMINSTALLATION NEUTRAL-TO-GROUND BOND SWITCHING RV AND MARINE APPLICATIONSPage AC SOURCE Figure 14, Neutral-To-Ground Bond Switching Neutral Bonded To GroundINSTALLATION PageONE GROUND FOR ALL EQUIPMENT GROUNDING VS. LIGHTNINGKEEP EQUIPMENT CLOSE TOGETHER Figure 15, Multiple Point Ground SystemPage INSTALLATION 2001 Xantrex Technology, Inc Telephone 360/435-8826Page FUNCTIONAL TEST FUNCTIONAL TESTPage FUNCTIONAL TEST 2001 Xantrex Technology, Inc Telephone 360/435-8826OVERVIEW MENU SYSTEM MENU SYSTEMPage USER MENU MAP MENU SYSTEMMENU HEADINGS MENU ITEMSMENU SYSTEM SETUP MENU MAPMENU HEADINGS MENU ITEMSMENU HEADINGS USER MENUMENU SYSTEM PageGENERATOR MODE 2 MENU HEADING INVERTER MODE 1 MENU HEADINGMove cursor to Inverter OFF to reset Overcurrent INFORMATION DISPLAYGenerator sync errorNO Generator start errorNOGen max run time errorNO MENU SYSTEM5916 195th St NE Arlington, WA 98223 USA TRACE ENGINEERING 3 MENU HEADINGMENU SYSTEM PageNOTE The meters do not display a + symbol for positive values METERS 4 MENU HEADINGMENU SYSTEM PageAC1 & AC2 volts valid only when inverter synced to that input ERROR CAUSES 5 MENU HEADINGMENU SYSTEM PageMENU SYSTEM Battery voltage was above the HIGH BATTERY CUT OUT VDC setting. This can be caused by the solar array or other charging source not being regulated. Check the controller for proper operation. Some controllers have a “equalize” setting which over-rides the normal operation, allowing the battery voltage to be unregulated. Return the controller to the “normal” setting and check for proper operation. If you are using NiCad type batteries, you will need to increase the HIGH BATTERY CUT OUT VDC setting. The inverter will automatically reset once the battery voltage has dropped 1.5 volts below the HBCO setting for a 12 VDC system, 3 volts for a 24 VDC system and 6 volts for a 48 VDC systemPage To defeat timers set start = end GENERATOR TIMER 7 MENU HEADINGTIME OF DAY 6 MENU HEADING Gen doesn’t run during quiet time unless batt volts is less thanMENU SYSTEM SETUP MENUMENU HEADINGS PageMENU SYSTEM INVERTER SETUP 9 MENU HEADINGPage Set Grid Usage FLT SELL SLT LBXMENU SYSTEM This setting controls when the inverter turns off due to a low battery voltage condition. The inverter will turn off only after this level has been reached for the period of time set by the following item. When the automatic generator control system is used, the generator will be started when the battery voltage has dropped below this value for 30 seconds continuously. This will occur even during the quiet time period. This setting is not temperature compensatedPage battery temperature if the BTS sensor is installed BATTERY CHARGING 10 MENU HEADINGMENU SYSTEM PageSets the maximum amount of AC input current that the battery charger will use to charge the battery. This can be used to limit the charger output as well. The charger will “back-off” if the combination of AC loads and the charger reaches the AMPS AC setting of the AC INPUT connected to prevent overloading the source or tripping breakers. This process occurs automatically AC INPUTS 11 MENU HEADINGSMENU SYSTEM PageSets the AC load current that will initiate the automatic generator control system when the current remains above this setting continuously for the LOAD START DELAY MIN period GEN AUTO START SETUP 12 MENU HEADINGMENU SYSTEM PageMENU SYSTEM GEN STARTING DETAILS 13 MENU HEADINGPage INFORMATION DISPLAYMENU SYSTEM AUXILIARY RELAYS 14 MENU HEADINGPage Set Pre Crank seconds10Close on batt setpoint. Open on batt setpoint - hys Relays have 2 seconds delay on close, 0.1 sec delay on openMENU SYSTEM PageLOW BATTERY TRANSFER 16 MENU HEADING BULK CHARGE TRIGGER TIMER 15 MENU HEADINGSee menu 9 to enable LBX mode Make sure LBX is above LBCO volts MENU SYSTEMGRID USAGE TIMER 18 MENU HEADING BATTERY SELLING 17 MENU HEADINGSee menu 9 to enable SELL mode. Make sure LBX is above LBCO volts SELL modeSell and float modes use timer. SLT and LBX mode ignore timer INFORMATION FILE BATTERY 19 MENU HEADINGMENU SYSTEM PagePage MENU SYSTEM 2001 Xantrex Technology, Inc Telephone 360/435-8826OPERATION OPERATION Figure 17, Trace SW Series Inverter Simple Block DiagramTHEORY OF OPERATION PageFigure 18, Trace SW Series Inverter Output Waveform OPERATIONPage SW3024E / SW3048E POWER VS. EFFICIENCYSW4024 / SW4048 SW4548Epower INVERTER CAPACITY VS TEMPERATURETemperature C Figure 20, Inverter Capacity vs. TemperatureOPERATING MODES ADDITIONAL FEATURESOPERATION PageSEARCH MODE CONTROL INVERTER MODEBATTERYDC SETTING SEARCH MODE WATTSSETTING SEARCH MODE SPACING LOW BATTERY PROTECTIONADJUSTING THE LOW BATTERY PROTECTION OPERATIONBATTERY CHARGER MODEFigure 21, Three-Stage Battery Charging THREE STAGE CHARGING PROCESSFigure 22, BTS Battery Temperature Sensor BATTERY TEMPERATURE SENSOR BTSCHARGER ONLY OPERATION AC INPUT REQUIREMENTSDELAY PERIOD RECOMMENDED BATTERY CHARGER SETTINGSAC CURRENT LEVEL FREQUENCYTYPICAL BULK AND FLOAT SETPOINTS FOR COMMON BATTERY TYPES Table 4, Charging Setpoints For Common Battery TypesBattery Type EQUALIZING BATTERIES UNSEALED OR VENTED BATTERIES ONLYOPERATION To start the equalization process either manually or automaticallyPage TRANSFERRING UPON AVAILABILITY OF AC POWER INVERTER/CHARGER MODETRANSFERRING BASED ON BATTERY VOLTAGE UTILITY GRID AC AC GENERATORWhile connected to the utility, the battery charger will be engaged. Some applications may want to allow the alternate power source solar, wind or hydro to recharge the battery instead of allowing the utility to provide the power. The only option is to program the SET MAX CHARGE AMPS AC menu item under the BATTERY CHARGING 10 menu heading to the minimum value, 1 amp AC, and set the BULK VOLTS and FLOAT VOLTS settings, also under the BATTERY CHARGING 10 menu heading, to a low value TRANSFER TIMEOPERATION PageGENERATOR GENERATOR SUPPORT MODEBATTERY OPERATION120 VAC VS. 120/240 VAC GENERATORS GENERATOR SUPPORT/OVERLOAD PROTECTIONOPERATION PageDC BATTERY AUTOMATIC GENERATOR CONTROL MODEAC GENERATOR CONTROL INVERTER/ CHARGERGENERATOR STARTING SCENARIOS GEN CONTROL RELAYSAUTOMATICALLY OPERATIONMANUALLY GENERATOR STARTING AND STOPPING CONFIGURATIONSOPERATION Page2 WIRE TYPE GENERATOR TWO WIRE START GENERATORSFigure 23, Two Wire Start Wiring Diagram GENERATOR AUTO START REQUIREMENTS AND TYPESFigure 25, Three-Wire Start Wiring Diagram ONAN Type THREE-WIRE START GENERATORSHONDA TYPE GENERATOR OPERATIONGENERATOR CONTROL SEQUENCE 3-TO-2 WIRE CONVERTERSFigure 26, Relay RY7 and RY8 Sequence OPERATIONGENERATOR STOP COOL DOWN PERIOD GENERATOR ERROR CAUSESOPERATION PageAn automatic equalization charge process is available in the SW Series Inverter/Charger. To start the equalization process, select EQ from the SET GENERATOR menu item, accessible by pressing the green GEN MENU button on the Control Panel EQUALIZATION CHARGING, AUTOMATIC GENERATOR CONTROL SYSTEMOPERATION PageGENERATOR AC INVERTER/ CHARGER DC BATTERY UTILITY BACKUP MODEUTILITY GRID MAINBATTERY REQUIREMENTS USING SLT MODE SILENT MODEUTILITY SUPPORT/OVERLOAD PROTECTION OPERATIONGROUND FAULT UTILITY INTERACTIVE MODEUTILITY GRID kWh METER AC OUTDOOR AC DISCONNECT MAIN AC LOADS AC NOT PROVIDEDSOLAR ARRAY WITH BACK-UPUTILITY INTERACTIVE ISLANDING PROTECTION THEORY OF OPERATIONWhen SELL mode is selected from the SET GRID USAGE menu item located under the INVERTER SETUP 9 menu heading in the SETUP MENU, the inverter will move any excess power not required to charge the batteries into the utility grid OPERATIONBattery Sell Volts SELLING POWER - FROM A DC CHARGING SOURCEDC Setting POSITIVE + = Inverter is drawing power from gridPower stored in the batteries can also be sold into the utility grid. This can be used together with the solar array or alone without a solar array. The inverter can be programmed to sell the energy in the batteries at a specific time and then to recharge the batteries at another time. Both the discharge level and discharge rate can be adjusted to control the battery selling process SELLING POWER - STORED IN THE BATTERIESOPERATION Page15 menu heading is used to trigger a bulk charge cycle BATTERY REGULATION LEVEL - SELL MODEBATTERY REQUIREMENTS OPERATIONBACKUP OF CRITICAL AC UTILITY INTERACTIVE OPERATION WITH UTILITY BACKUPUTILITY INTERACTIVE LINE-TIE SYSTEM WITHBATTERY BANK OVERVOLTAGE PROTECTION FOR THE BATTERY IN SELL MODEFigure 30, Overvoltage Protection for Battery SOLAR ARRAYINVERTER/ CHARGER DC BATTERY ENERGY MANAGEMENT MODEOPERATION IN BRIEFPage OPERATIONIN BRIEF PEAK LOAD SHAVING MODEINVERTER/ CHARGER DC BATTERY OPERATIONSOLAR ARRAY DC GROUND FAULT PROTECTION LOW BATTERY TRANSFER LBX MODEUTILITY GRID kWH METER AC AC LOADSAC MAIN PANEL AC LOADS SUB-PANEL AC INVERTER CHARGEROPERATION Once the system has transferred back to the battery, the battery voltage will continue to increase if the power from the alternative source exceeds the loads. This can result in the battery voltage reaching the HIGH BATTERY CUT OUT VDC setting unless a charge control device limits the battery voltage. Note that the LOW BATTERY CUT IN VDC setting must be set below the external charge controllers regulation setting or the system would never transfer back to the battery. The best compromise involves setting the BULK VOLTS DC equal to the FLOAT VOLTS DC default value, and setting the LOW BATTERY CUT IN VDC setting to the default BULK VOLTS DC setting. Make sure the external charge controller is set slightly higher than the LOW BATTERY CUT IN VDC setting so that the voltage can be reached without the charging source shutting offPage INPUT/OUTPUT BYPASS BREAKER SWITCH - 240 VAC LOADS USING MULTIPLE INVERTERS“SERIES” STACKED OPERATION OPERATION“PARALLEL” STACKED OPERATION GENERATOR CONTROL SETTINGS240 VAC/60 HZ ONLY ELECTRICAL SYSTEMS OPERATIONAUTOMATIC GENERATOR CONTROL WITH MULTIPLE INVERTERS BATTERY CHARGING WITH MULTIPLE INVERTERSThe inverters can operate in parallel as battery chargers from the same AC source connected to the same battery. The AC input terminals and DC terminals would all be in parallel. The inverters will synchronize individually to the AC source and then connect OPERATIONPage OPERATION 2001 Xantrex Technology, Inc Telephone 360/435-8826SELECTION OF BATTERY TYPE BATTERY TYPESTARTING BATTERY TELEPHONE COMPANY BATTERYTECHNICAL INFORMATION NICAD AND NICKEL IRON NIFE BATTERYPage 100 SEALED LEAD ACID BATTERIESESTIMATING BATTERY REQUIREMENTS BATTERY SIZINGPage 101 Table 5, Typical Wattage Of Common AppliancesEXAMPLE BATTERY BANK SIZINGPage 102 5,139Page 103 WORKSHEETTECHNICAL INFORMATION WATTSTable 6, Battery Charging Charging Setpoints BATTERY CARE AND MAINTENANCEPage 104 TYPICAL BULK AND FLOAT SETPOINTS FOR COMMON BATTERY TYPESBATTERY STATE OF CHARGE MONTHLY MAINTENANCETable 7, Battery State of Charge Voltage Page 105BATTERY ENCLOSURES BATTERY INSTALLATIONBATTERY TEMPERATURE Page 106Each individual 6-volt battery capacity = 100 amp hours BATTERY HOOK-UP CONFIGURATIONSFigure 31, Series Configuration 6-Volt Battery Wiring Total Battery CapacityFigure 33, Parallel Configuration 12-Volt Battery Wiring Each individual 12-volt battery capacity = 50 amp hoursPARALLEL CONNECTION SERIES - PARALLEL CONNECTIONFigure 35, Series-Parallel Configuration 12-Volt Battery Wiring Total Battery CapacityPage 109 6V 6VDistance Between Battery Cables Inductance in micro-Henries BATTERY CABLE INDUCTANCETable 8, Battery Cable Inductance Page 110RESISTIVE LOADS APPLICATIONSINDUCTIVE LOADS Page 111INVERTER - If ERROR LED comes on, see ERROR CAUSES section TROUBLESHOOTING GUIDEPROBLEM SOLUTIONPage 113 BATTERY CHARGER - If ERROR LED comes on, see ERROR CAUSES sectionPage TROUBLESHOOTING GUIDETROUBLESHOOTING GUIDE Page 114SOLUTION TECHNICAL INFORMATIONPage 115 INVERTER/CHARGER TERMINOLOGYDigital VoltMeter DVM TECHNICAL INFORMATIONFigure 36, AC Waveforms Page 116TECHNICAL INFORMATION Stacking Page 117TECHNICAL INFORMATION Note All specifications are subject to change without notice SPECIFICATIONS AND FEATURES 60 Hz ModelsPage 118 MODELPage 119 SPECIFICATIONS AND FEATURES 50 Hz ModelsSW2612E SW3024E SW3048E SW4548E SW3024J SW4048J SW4548APage 120 DIMENSIONSTECHNICAL INFORMATION  2001 Xantrex Technology, IncPage 121 INSTALLATION DIAGRAMSTECHNICAL INFORMATION TECHNICAL INFORMATION Page 122 2001 Xantrex Technology, Inc Telephone 360/435-8826USER MENU USER SETTINGS WORKSHEETSPage 123 SW Series Inverter/Charger - Model SWPage 124 SETUP MENU - 12 VDC 120 VAC/60HZ MODELSDEFAULT SETTINGS USER SETTINGSPage 125 SETUP MENU - 24 VDC 120 VAC/60HZ MODELSDEFAULT SETTINGS USER SETTINGSPage 126 SETUP MENU - 48 VDC 120 VAC/60HZ MODELSDEFAULT SETTINGS USER SETTINGSTECHNICAL INFORMATION Page 127 2001 Xantrex Technology, Inc Telephone 360/435-8826OPTIONS APPENDIXSWRC SWCATM500 TRACE METER BATTERY STATUS MONITOR SW SERIES POWER PANEL SYSTEMSOTHER PRODUCTS C40 MULTI-FUNCTION CONTROLLERTable 10, AWG to Metric Wire Conversion Chart Table 9, Power Consumption Of Common AppliancesREFERENCE TABLES AND GRAPHS Page 130Table 12, Battery Cable to Maximum Breaker/Fuse Size Table 11, Minimum Recommended Battery Cable Size vs. Cable LengthPage 131 NEC AMPS2Table 15, Safety Ground Wire Size Table Table 13, Recommended Minimum AC Wire Sizes 75 CBattery DC Disconnect Size Minimum Size of Copper Ground WirePreparation for Storage Storage ChecklistPage 133 Interior StorageAPPENDIX Page 134 2001 Xantrex Technology, Inc Telephone 360/435-8826LIMITED WARRANTY WARRANTY/REPAIR INFORMATION WARRANTY/REPAIR INFORMATIONWARRANTY REGISTRATION LIFE SUPPORT POLICYWARRANTY OR REPAIR SERVICE REQUIRED WARRANTY/REPAIR INFORMATIONPage 136 Page 137 INDEXHook Up Configurations INDEXINDEX PageLow Battery Cut Out VDC Page 139INDEX Output WaveformPage INDEXInstallation Guidelines Page 141INDEX Stored In The BatteriesINDEX Page 142

SW Series Inverter/Chargers

With Revision 4.01 Software

Owner’s Manual

 2001 Xantrex Technology, Inc.

Telephone: 360/435-8826

5916 - 195th Street N. E.

Arlington, WA 98223

Rev. C: February 2001